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GUIDEFORM SPECIFICATION FOR S-4 UPS SYSTEM 40-150 kVA 3-PHASE OUTPUT

The attached specification is intended for use by consulting engineers to provide bidding specifications for products with the quality and performance characteristics provided by CYBEREX product listed above. This same specification can be used as a description of the listed CYBEREX product by substituting "provides" for "shall provide" or similar wording. This specification is indexed according to the Commercial Standard Instructions format and without this cover page has no reference to a particular vendor or product. The latest revision number appears on the upper right of the first page. This is document 94-73-010050 Data provided courtesy of: CYBEREX, INC. 7171 Industrial Park Blvd. Mentor, Ohio 44060 Call Toll-Free 1-800-631-1236 In Ohio call (216) 946-1783 FAX (216) 946-5963 TELEX 980644 SECTION 16611 UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS)

PART I GENERAL 1.01 WORK INCLUDED A. CYBEREX INC. shall furnish a complete Uninterruptible Power Supply system, as specified herein, and hereafter referred to as the "UPS", to provide continuous, regulated AC power to critical loads under normal and abnormal conditions, including loss of the utility AC power. The UPS shall be completely solid-state except for bypass switches which shall be mechanical. B. The following shall be furnished along with the equipment: 1. 2. 3. Factory testing. Protective packing. Documentation.

1.02 RELATED WORK A. The UPS shall be installed by others in accordance with the manufacturer's recommendations. 1.03SYSTEM DESCRIPTION A. The UPS system shall consist of a UPS module, a storage battery, a remote alarm panel and a battery disconnect switch. The AC output of the UPS module will be connected to the critical loads. The storage battery will be connected to the DC input of the UPS module through the battery disconnect switch. Utility AC power will be connected to the normal source AC input of the UPS module. Also, utility power will be connected to the alternate AC input of the UPS module to provide power to the critical loads during maintenance. The alternate AC input must match the UPS output in voltage, phasing and ampacity. B. Definitions. 1. 2. 3. 4. UPS Module - The portion of the UPS system which contains the rectifier/charger, inverter, static transfer switch, maintenance bypass switch, controls, instruments and indicators. Rectifier - The portion of the UPS module which converts the normal source AC input power to DC power for the inverter input and for charging the storage battery. Battery Charger - The portion of the UPS module which converts the normal source AC input power to DC power for charging the storage battery. DC Static Switch - The portion of the UPS module that connects the storage battery to the DC input of the inverter when the normal source AC fails and removes the storage battery when the normal source returns. Inverter - The portion of the UPS module which converts DC power, from either the rectifier/charger or the storage battery, to regulated and filtered AC power which is supplied to the critical loads through the static transfer switch. Static Transfer Switch - The portion of the UPS module which automatically transfers the critical loads, without interruption, from the inverter output to the alternate AC power source

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in the event of an overload or degradation of the inverter's performance. 7. Maintenance Bypass Switch - The portion of the UPS module which is used to connect the alternate AC power source to the critical loads while electrically isolating the static transfer switch and inverter for maintenance purposes. Storage Battery - The battery system which provides DC power to the inverter input when the normal AC input power to the UPS module fails or in the event that the rectifier/charger should fail. Battery Disconnect Switch - The device used to electrically isolate the storage battery from the UPS module for maintenance purposes and which provides overcurrent protection at the storage battery output.

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10. Critical Loads - Those loads which require regulated continuous power and which are connected to the output of the UPS module. C. The UPS system configuration shall be a single UPS module rated to supply the full load as specified herein. 1.04SYSTEM OPERATION A. Normal - The inverter shall supply AC power continuously to the critical loads through the static transfer switch. The inverter output shall be synchronized with the alternate AC power source provided that the alternate AC power source is within the specified frequency range. The rectifier/charger shall convert the normal AC input power to DC power for the inverter and for float charging the storage battery. B. Loss of Normal AC Input Power - The storage battery shall supply DC power to the inverter so that there is no interruption of AC power to the critical loads whenever the normal AC input power source of the UPS module deviates from the specified tolerances or fails completely. The battery shall continue to supply power to the inverter for the specified protection time. C. Return of Normal AC Power Source - The rectifier shall start and assume the DC load from the battery when the normal AC power source returns. The rectifier shall then simultaneously supply the inverter with DC power and recharge the storage battery. This shall be an automatic function and shall cause no disturbance to the critical loads. D. Transfer to Alternate Source - If the static transfer switch senses an overload, an inverter shutdown signal or degradation of the inverter output, then it shall automatically transfer the critical loads from the inverter output to the alternate AC power source without an interruption of power. If the alternate AC power source is below normal voltage limits, then the transfer shall be inhibited. E. Retransfer to Inverter - The static transfer switch shall be capable of automatically retransferring the load back to the inverter after the inverter has returned to normal voltage and stabilized for a period of time. Retransfer shall not occur, if the two sources are not in phase. F. Downgrade - If the battery is taken out of service for maintenance, it shall be disconnected from the rectifier/charger and inverter by the battery disconnect switch. The UPS shall continue to function and meet all the performance criteria specified herein except for the battery reserve time capability.

1.05 QUALITY ASSURANCE A. The manufacturer will have a quality assurance program with checks on incoming parts, modular assemblies and final products. A final test procedure for the product shall include a check of all performance specifications and a minimum 24-hour "burn-in". An on-site test procedure shall include a check of controls and indicators after installation of the equipment. 1.06REFERENCES A. ANSI/NFPA 70 (1987) - All conductors shall be sized according to their current ratings with appropriate derating when required. 1.07SUBMITTALS A. With Proposals - Catalog cuts and/or data sheets describing the proposed equipment shall be submitted with the proposal. A user's listing shall be furnished giving company names, locations and UPS's installed. All deviations to this specification shall be listed and included with the proposal. B. After Receipt of Order - A minimum of two sets of installation drawings showing outline dimensions, weights, connections and a one-line diagram of the UPS shall be sent to the purchaser to be used in planning the installation of the system. C. After Construction of Equipment. 1. Two copies of drawings shall be furnished for each of the following: a. b. c. 2. Equipment installation outline. Connection diagram for external cabling. Equipment internal wiring diagram.

Two instruction manuals shall be furnished and shall include as a minimum the following: a. b. c. d. e. Installation procedures. Operation procedures. Servicing procedures.(OPTIONAL) Troubleshooting instructions. List of recommended spare parts.

3.

One certified copy of the final test report shall be furnished with the equipment.

D. After Installation of Equipment - A signed field service report describing start-up and on-site testing shall be furnished with the invoice for the service trip. 1.08DELIVERY, STORAGE AND HANDLING A. The equipment shall be shipped on a wooden pallet suitable for forklift handling. The equipment shall be covered with clear plastic sheeting to prevent dust and dirt from entering the cabinet during shipment and storage. A wooden protective framework shall then be placed around the cabinet to prevent damage to the cabinet during shipment.

1.09 SITE CONDITIONS A. The equipment shall be suitable for installation indoors with ambient temperatures from 0 - 40o C. (32 - 104o F.) and relative humidity from 0 - 95%. 1.10 WARRANTY A. The manufacturer shall state his warranty of the equipment. In no case shall it be less than 12 months after start-up or 18 months after shipment, whichever occurs first. PART II PRODUCT 2.01ELECTRICAL CHARACTERISTICS A. UPS Module Normal Source Input. 1. 2. 3. 4. Voltage VAC, 3 Phase, 3 Wire.

Voltage Range - ± 10% with equalizing capability. Frequency - 60 Hertz ± 5%. Power Factor - 0.95 lagging at nominal input voltage.

B. UPS Module Alternate Input (must be the same as 2.01.C). 1. 2. 3. Voltage VAC, Phase, Wire.

Frequency - 60 Hertz. Power Rating kVA.

C. UPS Module Output. 1. 2. 3. 4. Voltage VAC, Phase, Wire.

Frequency - 60 Hertz. Power Rating KW, kVA at 0.8 power factor.

Voltage Regulation ± 1% nominal for any of the following conditions. a. b. c. d. No load to full load. 1.0 to 0.8 lagging power factor. Minimum to maximum DC input voltage. 0 to 50o C. ambient temperature.

5. 6.

Voltage Transient Response - 10% maximum deviation (average over 1/2 cycle) with recovery to within 5% after 1/2 cycle for 100% load application or removal. Voltage Adjustability - ± 5%.

7. 8. 9.

Voltage Unbalance - 5% maximum, line to line or line to neutral, with 100% load unbalance. Phase Separation - 120o ±5o with 100% load unbalance. Harmonic Distortion - 5% THD maximum with current waveshape crest factor under 2.0.

10. Frequency Stability - ± 01% free-running. 11. Frequency Slew Rate - 1.0 Hertz per second maximum. 12. Frequency Adjustability - Crystal controlled. 13. Overload Capacity (Static Bypass). a. b. c. 125% continuous. 150% for 30 seconds. 750% for 10 milliseconds.

D. Storage Battery. 1. 2. 3. Voltage - As required by the inverter. Protection Time Minutes. .

Rack Bracing - Seismic Zone

2.02 RECTIFIER A. The rectifier shall consist of an input circuit breaker, an auto transformer, surge suppressors and a solid-state three phase rectifier. B. Overcurrent Protection. 1. 2. The input of the rectifier shall be protected by an automatic circuit breaker. The output of the rectifier shall be fused.

C. Input Transformer. 1. The input auto transformer to the rectifier shall be a two phase type with copper windings.

D. Surge Suppressors. 1. The rectifier shall be furnished with surge suppressors.

E. Output Filter. 1. The rectifier shall be furnished with output filtering to limit ripple currents into the inverter.

2.03 BATTERY CHARGER

A. Control Circuitry. 1. 2. 3. The battery charger shall be equipped with control circuitry to provide constant DC voltage regulation of ± 1% for standby (float) battery operation. The control circuitry shall electronically current limit the output of the battery charger by drooping the DC voltage whenever the DC current exceeds a preset limit. The control circuitry shall automatically provide a boost (equalize) voltage after a failure of the normal input AC power. This function shall be selectable by a switch on the system panel. Provisions shall be made to also initiate equalization manually.

B. Filtering 1. The battery charger shall be furnished with output filtering to limit ripple currents into the battery to less then 1%.

2.04 DC STATIC SWITCH A. The DC static switch shall consist of DC a switching system, isolating diodes, filtering inductors and evaluation and control circuitry. B. DC SWITCHING SYSTEM 1. The DC switching system shall consist of the switching components required to transfer the DC load (inverter) to the battery system when the AC normal input deviates outside of the operating window of the rectifier or when the DC voltage out of the rectifier goes outside of the inverter operating window. The DC switching system shall also be able to disconnect the battery system from the DC load upon the return of the AC source to the correct window to enable the battery charger to recharge the battery system. The control circuitry shall consist of the necessary circuitry to evaluate and control the DC switching system and associated systems. The sensing and evaluation circuits shall be adjustable for precise determination of the operating thresholds. LED's shall be used for quick determination of the circuitry status.

2.

2.05 INVERTER A. The inverter shall consist of DC filter capacitors, DC surge protection, a solid-state pulse width modulated (PWM) inverter, an output isolation transformer, an output filter and control circuitry to provide precise AC voltage regulation and electronically controlled current limiting. B. Overcurrent Protection. 1. 2. The inverter input shall be protected by fast acting fusing to prevent damage to the solid-state devices in the inverter bridges. The inverter output shall be both fused and electronically current limited.

C. DC Filter Capacitors. 1. The input of the inverter shall have banks of filter capacitors.

D. DC Surge Protection. 1. The inverter input shall have DC surge protection to assure proper operation in the event that there are surges or spikes on the inverter input. The inverter input shall be protected against a 4000 volt transient for 100 microseconds from a 40 ohm dynamic source impedance.

E. Pulse Width Modulated (PWM) Inverter. 1. F. The inverter shall be a PWM type to minimize the number of power semiconductors for increased reliability and to provide improved transient response.

Output Transformer. 1. The inverter shall be furnished with an isolation type output transformer with copper windings.

G. Output Filter. 1. The inverter shall have an output filter to maintain the total harmonic distortion (THD) of the output voltage to the specified limits.

H. Control Circuitry. 1. 2. 3. 4. The inverter shall be provided with control circuitry to provide constant AC voltage regulation as specified. The control circuitry shall electronically current limit the output of the inverter by drooping the AC voltage when the output current exceeds a preset limit. The circuitry shall provide a low voltage initial start-up of the inverter and ramp up to full voltage in less than 5 seconds. The control circuitry shall automatically synchronize and phase lock the inverter output to the alternate power source as long as the source is within 60 ± 0.5 Hertz. If the alternate power source is not within these limits, then the control circuitry shall break synchronization and lock to an internal crystal oscillator. The control circuitry shall interface with a DC low voltage sensor and turn off the inverter at the 1.75 volts per cell level to prevent damage to the battery. Test points shall be provided to facilitate adjustments and diagnoses. Provisions shall be made for easily testing logic circuitry without operating the power circuits. Light emitting diodes shall be placed on the circuits for verification of operation.

5. 6. 7. 8.

2.06 STATIC TRANSFER SWITCH

A. The static transfer switch shall consist of two pairs of Silicon Controlled Rectifiers (SCR's) per phase with each pair connected in inverse parallel (back to back). One set of SCR's shall be connected to the inverter while the other set of SCR's is connected to the alternate or bypass, power source. The outputs of the two sets of SCR's are connected together and furnish power to the critical loads. B. Inverter Failure - If the inverter is out of normal limits due to fast or slow undervoltages or due to overvoltages, the static transfer switch shall turn on the alternate source SCR's to provide power to the loads from the alternate power source. At the same time, the inverter side shall be turned off to prevent the alternate power source from backfeeding power to the inverter. If the alternate power source is not within normal voltage limits, then the transfer shall be inhibited. C. Retransfer to Inverter - The static transfer switch shall be capable of automatically retransferring the load back to the inverter after the inverter has returned to normal voltage and stabilized for a period of time. Retransfer shall not occur, whether initiated manually or automatically, if the two sources are not in phase. D. Overload - If an overload is detected, the static transfer switch shall operate as described in 2.04.B. and C. above. E. Overcurrent Protection - Fuses shall be placed in the inverter and alternate sources of the static transfer switch. F. Surge Protection - The static transfer switch shall have surge protection on the alternate source side.

G. Transfer Conditions. 1. The static transfer switch shall transfer from the inverter to the alternate power source for the following conditions: a. Inverter undervoltage. (Any phase) 1. b. 90% of nominal.

Inverter overvoltage. (Any phase) 1. 110% of nominal.

c.

Inverter overload. (Any phase)

d. Blown fuse in the inverter. e. 2. Manual signal.

The static transfer switch shall inhibit transfer to the alternate source for the following conditions: a. Alternate source undervoltage. (Any phase) 1. Less than 80% of nominal.

I.

Automatic Retransfer Conditions - The system shall automatically retransfer the load to the inverter provided all of the following conditions are met: 1. 2. The inverter and the alternate source are in phase. Inverter voltage is within ± 10% of nominal for more than five seconds on all phases.

J.

Transfer Sensing Time - Maximum transfer sensing time for loss of inverter voltage shall be 1/4 cycle maximum.

K. Transfer Time - Maximum transfer time to switch from inverter to alternate power source shall be 100 microseconds. L. Inter-Source Current Protection - Load current shall be monitored to minimize energy transfer between the two sources when transferring from inverter to alternate. 2.07MAINTENANCE BYPASS SWITCH A. A manually operated maintenance bypass switching arrangement shall be provided which permits bypassing the critical loads to the alternate AC power source without interruption of power to those loads, and at the same time, electrically isolates the static transfer switch and inverter from the alternate power source. 2.08 CONTROLS A. The following controls shall be included on, or inside of, the UPS module cabinet: 1. Rectifier & Charger. a. b. c. d. e. f. 2. Input automatic circuit breaker. DC float voltage adjustment. DC boost (equalize) voltage adjustment. Boost (equalize) voltage timer adjustment. Boost (equalize) voltage timer initiate pushbutton. Boost (equalize) voltage timer reset pushbutton.

Inverter. a. b. c. d. Inverter start pushbutton. Inverter stop pushbutton. DC input undervoltage shutoff adjustment. Output AC voltage adjustment.

3.

Static transfer Switch. a. b. c. d. Test transfer switch. Transfer setting adjustments. Maintenance bypass switch. Alarm reset.

2.09 INDICATORS

A. The following status and alarm functions shall be monitored and displayed on the front of the UPS module cabinet: 1. Status indications. a. 2. Static transfer switch in inverter position.

Alarm Indications. a. b. c. d. e. f. g. h. i. On battery. High/low battery. DC link high/low. Alternate source failure. Static transfer switch in alternate source position. Inverter overload. Inverter high/low voltage. Inverter power stage trip off. Low battery trip.

2.10 ALARM CONTACTS (OPTIONAL) A. The following functions shall have alarm contacts (SPDT 2 Ampere rating) available for connection to purchaser's alarm system or to the remote alarm panel. These alarms shall latch until reset after the alarm condition has cleared. 1. 2. 3. On alternate. On battery. Alternate source failure.

2.11 REMOTE ALARM PANEL (OPTIONAL) A. A wall mounted remote alarm panel shall be furnished. It shall have an audible alarm, an alarm silence acknowledge pushbutton and lamps for the following alarm conditions: 1. 2. On battery. Summary alarm.

2.12 MICROPROCESSOR MONITORING/METERING A. This system shall be a programmable microprocessor based controller with the following operating functions: 1. 2. 3. 2 lines x 20 character alphanumeric LCD display. Telephone type keyboard for controls. RS232 communications port.

B. The following metering functions can be measured and displayed at either the LCD display or directed to the RS232 port.

1. 2. 3. 4.

Battery volts and amps. DC link volts. AC volts and amps on system input. AC volts and amps on system output or alternate line.

2.13 DESIGN A. Life - The system shall use components of adequate rating to provide an expected service life of twenty years continuous duty and ten years without component replacement. The system shall contain no continuously moving parts other than cooling fans which shall have permanently lubricated bearings. B. Maintenance - Provisions shall be provided for testing the control circuits while the critical loads are bypassed to one of the power sources. All adjustments and tests shall be possible with the use of a standard volt-ohm-milliampere meter and oscilloscope. Test points and diagnostic lights shall be provided to allow easy adjustment of the controls. Control circuits shall be mounted on etched circuit boards with plug-in connections for ease and speed of repairs. 2.14 CONSTRUCTION A. Enclosure - The UPS electronics shall be housed in a code gauge steel, NEMA-1 enclosure requiring access from the front only for all servicing adjustments and connections. Access shall be through a hinged door with a tumbler lock and latch handle. The enclosure shall be primed and painted inside and outside with a suitable semi-gloss enamel. The enclosure shall be a free-standing floor mount design with removable side and back panels to provide flexibility of installation configuration. Enclosure shall be installable with back to wall and with equipment adjacent to either or both sides. B. Layout - Modules and subassemblies shall be mounted in open construction style so that each may be easily replaced. The equipment shall be constructed so that each power component can be replaced without a soldering iron or special tools. Cable and conduit connections shall be through the top of the cabinet. C. Material and Workmanship. 1. 2. 3. 4. Workmanship shall be first class in every respect. All material shall be new and of best commercial grade. Brackets and securing hardware shall be electroplated with corrosion resistant material. Internal wiring conductors shall be combined into cables or bundles and shall be tied securely together.

2.15 COOLING A. Cooling shall be by fans.

2.16 STORAGE BATTERY A. The storage battery shall have sufficient capacity to maintain the UPS output at full rated load for the time specified herein. The battery shall be designed for use with UPS modules and shall be equipped with safety vents on the containers. The battery shall be the sealed lead-calcium type. B. Voltages. 1. 2. 3. Floating - 2.25 volts per cell. Boost (equalize) - 2.35 volts per cell. Final discharge - 1.75 volts per cell.

C. The storage battery shall be furnished with rack(s), connecting hardware and standard service accessories. The battery shall be delivered charged and filled, ready for service. 2.17BATTERY DISCONNECT SWITCH A. A fusible safety switch rated for the proper DC voltage and final discharge ampacity shall be furnished with the UPS module if a rack mounted battery system is supplied. This switch shall be placed at the output of the storage battery. Fuses shall be selected and installed to coordinate with the battery cable sizing. This shall be done on-site by the installing party. PART III EXECUTION 3.01MANUFACTURING A. The manufacturer shall design, build, test and arrange for shipment of the UPS. B. The manufacturer shall prepare and deliver the required drawings and instruction manuals with the equipment. 3.02SITE PREPARATION A. The owner shall prepare the site for installation of the equipment.

3.03INSTALLATION A. The owner shall arrange for local electricians to install the equipment. B. The equipment shall be installed in accordance with local codes and the manufacturer's recommendations. 3.04FIELD QUALITY CONTROL A. If requested by the owner, the equipment shall be checked out and started by a field service representative from the equipment manufacturer. A signed field service report shall then be submitted after the equipment is operational.

3.05 SPARES A. A list of manufacturer's recommended spare parts shall be submitted with the manuals.

END OF SECTION

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